Metal profiled sheet, without exaggeration, can be called the most versatile building material. Due to the high demand, its production, and, as a result, the manufacture and sale of machines for the production of corrugated board, is a very profitable business.
An example of a corrugated board machine with partial automation
There are two main types of equipment for the production of corrugated board - these are manual machines used to produce small volumes of corrugated board, and automatic and semi-automatic rolling mills, which produce metal profiled sheet on an industrial scale.
Manual machine for the production of corrugated board
Manual profiled sheet machine can do profiling sheet metal up to 2.5 m long and is an alternative to powerful industrial rolling mills in cases where you need to produce small batches of corrugated board.
For example, such a machine is almost indispensable in cases where it is necessary to mount roofing at remote sites. In these cases, the delivery of a metal profiled sheet to the site can often be much more expensive than the cost of its manufacture.
The manual profiled sheet machine is easy to maintain and is driven by human muscle power. Moreover, due to the leverage system, a lot of effort is not required.
A manual corrugated sheeting machine, which costs about $2,000, will pay for itself within two to three weeks, even if it only produces 50-100 corrugated sheets per day. Provided that the productivity of such machines can reach 300 m² of profiled sheet per day, and even more. As payback example such a solution, we will calculate the cost of a profiled sheet produced on such a machine.
Example
The average price of rolled thin-sheet galvanized steel is about 1300-1500 US dollars per ton. From this amount of metal it is possible, using manual machine for corrugated sheet, produce approximately 250 m² of profiled sheet in just one day. Knowing that the price of galvanized steel profiled sheet is about 8 USD per one square meter, we can calculate that the cost of 250 m² will be 2000 US dollars. Thus, in addition to the cost of the metal, buying such a quantity of finished corrugated board, you will pay approximately 600 US dollars for its manufacture.
Based on the given data and taking into account how much a corrugated sheeting machine costs, it is easy to calculate the payback period for this investment. As a rule, it is only a few weeks.
The advantages and disadvantages of manual machines for corrugated board include the following:
- small production area necessary to accommodate such equipment;
- easy reconfiguration the number of waves or profile trapeziums;
- high performance (two workers in one shift can produce up to 300 m² of corrugated board);
- does not require electricity;
- reliability and simplicity in maintenance and operation;
Many modifications of such equipment, such as, for example, a machine for the manufacture of profiled sheet SPR-2.1, manufactured in Ukraine, can produce products not only from galvanized metal, but also from sheet steel with a polymeric protective and decorative coating.
Many machine-building enterprises in Europe and the CIS countries manufacture machines for the production of profiled sheets, so it will not be difficult to buy a machine for profiled sheeting.
The machine for the production of corrugated sheet works as follows:
- with the help of manual or stationary electromechanical scissors, a workpiece of the required size is cut out of sheet steel;
- the prepared workpiece is inserted into the machine with its side;
- with the help of a special handle, guides are actuated, bending the entire length of the metal sheet to the required angle;
- having thus formed one side of the profile trapezoid, the workpiece moves on the desktop to form the next trapezoid, and so on;
- after that, the sheet of metal unfolds and the other side of all the trapeziums of the corrugated board is formed in the same sequence;
You can buy a machine for the manufacture of corrugated board in a variety of modifications. They differ in the amount of equipment. So, for example, some types of machines are equipped with interchangeable dies for the manufacture of various grades of corrugated board. The kit of a manual machine may also include a special roller knife for cutting a metal sheet. Depending on the configuration and manufacturer, the price of a profiled sheet machine may differ several times, so be careful and choose only those options that you really need.
Industrial machines for the production of corrugated board
It is often said that in the factory, the profiled sheet is manufactured on rolling mills. But it is more correct to call them corrugated board production lines, since the rolling mill or the profiled sheet machine is only part of them.
Such a line usually includes the following equipment:
- cantilever or two-bearing decoiler;
- circular knife for cutting off a steel billet from a roll;
- multi-stand rolling mill;
- guillotine shears for cutting profiled sheet;
- receiving device with a retractable trolley;
- automated system line control.
You can buy a machine for the manufacture of profiled sheets in a different configuration. Many manufacturers offer additional options interchangeable modules of rolling mills. Interchangeable modules allow you to quickly switch from the production of one brand of profiled sheet to another, without wasting time on changing the rollers of the rolling mill.
The rolling mill is the key element of the corrugated board production line
You can also be offered a loader for mounting sheet steel coils on the decoiler and transporting the profiled sheet from the receiving device to the packing area or warehouse finished products.
Installing an automation system on the production line allows you to create a high-performance machine for the manufacture of corrugated board, the price of which will be slightly higher than semi-automatic options, but productivity will increase significantly. Namely, the payback period and profitability of investments depend on productivity.
The productivity of the line for the production of corrugated board is determined by the speed of rolling. For modern automated lines, this characteristic can reach 40 m/min. In fact, the productivity of the line is somewhat less than the rolling speed. This is due to the fact that some time is needed to cut each sheet of finished products. Therefore, at a rolling speed of 40 m/min, the line capacity will be 32-34 m/min.
Automation panel on a machine for the production of profiled sheets
The table below shows the cost of production lines for the production of certain types of profiles.
| Name equipment |
Machine for production corrugated board, price in rub. VAT included |
| Automated complex for the production of corrugated board С25-1050 |
2 137 500 |
| Automated complex for the production of corrugated board С18-1100 |
1 710 000 |
| Automated complex for the production of corrugated board С10-1100 |
1 898 820 |
| Automated complex for the production of corrugated board C21-1000 |
2 057 220 |
| Automated complex for the production of corrugated board H114 |
3 727 500 |
| Automated complex for the production of corrugated board H75-750 |
3 135 000 |
| Automated complex for the production of corrugated board С44-950 |
3 195 800 |
| Automated complex for the production of corrugated board C7 |
1 463 000 |
| Automated complex for the production of corrugated board NS35-1000 |
2 350 300 |
| Automated complex for the production of corrugated board H60-845 |
2 369 300 |
Today, corrugated board is increasingly popular with those who build modern buildings, erect fences, reliably strengthen partitions, and renew the look of old buildings. Also available with profiled steel wide opportunities for the erection of the original roof of a residential building or office building. Due to the high quality of rolled steel, profiled sheets can be used during the construction of structures such as warehouses and hangars.
Creating a high-quality building coating by rolling a strip through guide rollers is quite simple. Thanks to technology and equipment, it is possible to organize production in the available areas.
Sheets of corrugated board can be used as a material for such purposes:
walling different kind structures;
roofing for buildings for various purposes;
formwork manufacturing;
installation of partitions and fences.
Self-assembly of a machine for the manufacture of profiled sheets with your own hands
An automatic line for the production of profiled sheets is a very difficult task to assemble with your own hands. However, it is quite realistic to create a manual machine on your own, on which blanks can be bent to the desired angles and thus make sheets of corrugated board.
Here it should be taken into account that it will not be possible to produce profiled sheets of too large thickness on a home manual machine - the possible maximum is approximately 5 mm.
Drawings of machines for working with corrugated board
How to prepare supports and a table for feeding workpieces
To make a rolling machine yourself, you first need to assemble a frame to place all the components of the equipment in it. In this case, it is enough to establish reliable supports. They need to be attached to solid foundation- it is better if it is a concrete floor.Next, you need to start assembling the table, on the surface of which the workpiece will be fed into the machine. The table must have a length that is several times the length of the finished product. There must be enough free space on the surface to receive ready product. Optimal material table surface - aluminum sheet.
On the table you need to place a special bar, which with the help of bolts will fix the workpiece on the table. In the same way, the hand lever will be fixed, thanks to which sheets of material are fed along the table into the machine for corrugated board and installed desired angle filing.
How to install rolling shafts and start the fixture
It is rather difficult to assemble such a part of the structure as rolling shafts with your own hands, so it is easiest to buy ready-made ones. Today it will not be difficult to do this - you will find them at least in the market.By means of brackets made of metal corners, the shafts are fixed on the frame of the machine near the hand lever.
We tighten all the bolts not at full strength - now our home-made manual machine for the manufacture of corrugated board can be used to carry out the first run-in of the material. If the corrugated board, which is released on the machine, has the required shape, we fix the parts in their places, firmly tighten all the bolts. If the shape of the corrugated board does not meet our requirements, we adjust certain details and repeat the procedure.
It must be remembered that the machine for the production of corrugated board is equipment that is dangerous to operate. This machine is equipped with a large number of cutting and piercing elements, which, if safety precautions are not observed, can cause injury to the operator. Therefore, the machine may only be operated in protective clothing and goggles.
The production of a reliable, small in weight and inexpensive profiled sheet used in the construction industry of our days is carried out on special manual and automatic equipment.
1
Decking - universal modern material for the construction of low-rise buildings, wall cladding, roofing and other construction tasks, it is made from cold-rolled galvanized steel sheet. To give such rolled products the required shape, only two methods are used - hot and cold rolled. Both of these operations involve the passage of flat sheets of steel through special shafts.
Hot-rolled technology, due to its features, is available exclusively at large metallurgical plants.
But the cold rolling of steel billets in order to obtain from them can be performed in semi-professional and even amateur conditions. The main thing here is to choose the right equipment and learn how to use it correctly.
The cold rolled production technology consists of two consecutive procedures. First, the workpiece is passed through the rollers, and then the resulting corrugated board is cut according to the given geometric sections. The shape of the rollers determines, as you yourself understand, the shape of the finished product.
The simplest manual machine for the manufacture of profiled sheets is able to "give" us products of only one shape. In those cases when an automated line for the production of profiled sheets is used, it, as a rule, makes it possible to obtain products of different assortments and shapes. Such diversity is achieved due to the fact that automated equipment makes it possible to change the settings of the rollers.
2
Production is possible on installations of three main types:
- manual machine;
- mobile (mobile) equipment with partial automation of work operations;
Any person can use an elementary machine for the production of profiled sheets, but on condition that he is ready to make quite serious physical efforts to process steel sheets. On manual settings Usually billets of small thickness are rolled. The quality of the resulting products is at a low level. In most cases, such a machine is used for the production of profiled sheets for fences and fences.
Manual equipment does not have to be purchased in ready-made. On the Internet there are a huge number of detailed drawings and diagrams, guided by which you can independently make the simplest bending machine. We note again - it makes no sense to use it for the production of really high-quality profiled sheets. You simply won't be able to do anything.
Partially automated equipment for the production of corrugated board allows you to produce many times more professional products. Such units are equipped with an electric drive, they have a relatively small weight, which allows them to be carried and used directly at those facilities where low-rise construction is carried out, the construction of storage facilities for agricultural products and warehouses, hangars, fences, and so on.
Semi-automatic equipment is in no way inferior to fully automated lines in terms of the efficiency of its work and the quality of the profiled products. At the same time, it is mobile, which in some cases is of great importance.
A stationary automatic line is a whole complex of units. Depending on the specific configuration, it may include the following settings:
- directly rolling mill with rollers of several sizes;
- device for cutting profiled sheets;
- equipment for applying a polymer coating to finished products.
Also, as part of automated lines, there is sometimes a unit for loading operations. It is clear that such complexes have a high cost. But their performance is many times greater than the capabilities of manual and semi-automatic machines. It makes sense to invest in automatic equipment when you plan to work long and fruitfully in the field of manufacturing and selling profiled sheets with all kinds of geometric parameters.
3
Experts say that the minimum set of automated equipment for the production of high-quality profiled sheets should include the following mechanisms and fixtures:
The corrugated board production line is controlled by a special system. It can be both relatively simple and really complex. A simple control system does not provide high level automation of the production process, but people with low qualifications can work with it. But a complex equipment control complex increases the efficiency of the line. True, not everyone will be able to deal with such a system, for its use it is necessary to attract specialists with a large amount of technical knowledge.
4
Billet in the production of profiled sheet products on automatic lines directly depends on the number of rollers for rolling. They are placed in pairs one above the other. There is a small gap between the individual pairs of rollers. The steel sheet from which the corrugated board is made is slightly less than the specified gap in thickness (and sometimes these figures are the same).
The initial workpiece is passed through the rolling shafts, and this procedure is carried out several times in a row, since it is usually impossible to achieve the required sheet shape in one pass. In one run, the workpiece is bent between the rolls by a certain amount. At the same time, minimal pressure is exerted on it, which ensures a perfect result of the final deformation.
It is important not to overdo it with the number of pairs of rolls. If the workpiece is passed through too many of them, there is a possibility that the zinc coating of the steel sheet will be destroyed. In addition, the quality of profiled sheets is influenced by the quality of steel alloys from which rolling shafts are made and the level of cleanliness of their processing.
Experts advise to purchase equipment from foreign manufacturers (for example, Finnish) or domestic production lines, and never pay attention to units for the production of profiled sheets from Chinese companies. And the last. If possible, it is better to buy new rather than used profiled sheet production lines, since the technical capabilities of the latter are usually at a very low level due to their wear and tear.
It is not so difficult to make a bending machine with your own hands, but craftsmen, both home-made amateurs and self-employed entrepreneurs, use it little so far. Meanwhile, the price of only ready-made additional elements of the roof - valleys, ridges, cornice strips - and downpipes with gutters is several times higher than the cost of the material. The same applies to paintings (roofing sheets, quite ready for laying) with flanging edges for a double fold. And that's just roofing.
Meanwhile, many craftsmen still prefer to either buy ready-made parts, losing in earnings, or do the old fashioned way with a punch, losing potential customers - modern products should not have a horse-drawn look. What is wrong here: economics, technology, prejudices? Or maybe just ignorance? Maybe you just need a clear drawing of a bender, which you could build yourself in a shed, and use it for a long time and successfully? Let's try to figure it out.
Of the main indicators (economy, productivity, simplicity of design), it is also necessary to determine the durability, subject to a stable result of work. At the height of the season, when the day feeds the year, there is no time to bother with repair or adjustment, and with occasional use once a month, not every month you can do without special equipment at all, see below.
The minimum requirement is for a jack-of-all-trades who does roofing and tinsmith work from time to time if there are orders; it is unprofitable to buy such an industrial machine, it will not pay off. But then a home-made sheet bender must withstand at least 1200-1500 working cycles per season without compromising the quality of bending. Is there some more important point- corrugated board. More precisely, its independent production. It deserves special mention.
Qui prodest?
Translated from Latin - who benefits? Producing corrugated board on your own, at least for yourself, is a very popular material. Let's try to guess.
A manual pass-through type bender (see below) costs about $2000. It seems to be possible to turn a ton of galvanized 0.55 worth $ 1000 into 250 square meters on it in a day or two. m of corrugated board, which would cost $1,400 if purchased. It would seem a direct benefit; especially if you do not wait for a sale (the market is full of offers), but put it into business yourself. Yes, not so.
The corrugated board is not rolled in one pass - the corners in some places turn out to be constricted. Intercrystalline bonds in the metal are broken; the rough section of the bend is not always determined by sight and to the touch, but soon a crack will creep from it. And who will now give an order without a guarantee? Feel free to correct. For yours, of course.
You can reduce the pressure, but then the wave will go non-standard. The customer may not know the standards, but he will immediately see that the material is not the same. Put, be kind, like everyone else, or - goodbye, I'll turn to another. And I will tell my friends. Drive each sheet in several passes, changing the clamp or rollers? What kind of productivity with profitability.
The line (actually, the rolling mill) for corrugated board is a complex unit, see fig. Pay attention to the number and configuration of the rolls. The purpose of such a system is to disperse the residual stresses across the sheet so that they do not go beyond the permissible limits. Therefore, the wave is formed gradually.
Such equipment costs at least $20,000, made in China. Stable quality of finished products is guaranteed only for specific steel grades of a specific manufacturer. Power consumption - from 12 kW. Those. a specialized production area is needed with an appropriate power consumption limit and, although one operator is enough to serve. Is there an unsatisfied demand for corrugated board in your operating area (simply - in the vicinity accessible to you), allowing you to pay for it all in an acceptable time frame? And are you ready to start a very serious business with fierce competition?
Note to masters
Of course, it is not easy to “recapture” $2000 for an individual master. Therefore, let's try to figure out how to make a sheet bender yourself. Not for corrugated board, but for a variety of roofing and tinsmith work, on which you can also live well, and collect some money to start something more serious. A non-standard trifle is fundamentally not amenable to unification, but is always needed. And a homemade sheet bender can be a very good help here.
About purchased handbrakes
To put an end to the "firm" (the article is not advertising) and move on to homemade products, let's look briefly at what you can buy if you still need it. The market is clearly dominated by TAPCO and VanMark. And the domestic SKS-2, produced in Orsk, is almost unknown. For the price, all are about the same; width working area ours has 2.5 m against 3 for foreigners, but this is not a vice. 3 m is calculated on an inch system of measures (10 feet \u003d 3.05 m), and in metric 2.5 m is just more convenient.
But the Uralian is a passing type; it is possible, for example, to pull gutters up to 90x90 mm. Raising / lowering the traverse - eccentrics, no need to turn the flywheels. Complete with cutting blade. User reviews are not only favorable, enthusiastic. The general tone is "an indispensable hard worker."
History repeats itself. Nikita Khrushchev spoke about such situations live on the Central Television after his trip to America (this is when he beat his shoes on the UN platform and threatened to make everyone go to hell) Nikita Khrushchev. Like, in the States they know how to sell any obscene rubbish, but in our country they cannot properly submit the necessary good things.
Sheet bending structures
Drive unit
Bending and pressing equipment with a mechanical drive (a flywheel with a friction clutch and a crank or a falling weight with a system of pulleys, cables and levers) has a high efficiency, but is still a thing of the past. The mechanics gives a sharp impulse (blow) at the beginning of the working stroke, and towards the end it weakens. For bending/pressing, just the opposite is needed.
The efficiency of the electric drive decreases rapidly with a decrease in the size of the workpiece. To mold the corrugated board on the mill described above, 12 kW is enough. To make a flanging on the roof picture, you can’t do less than 1.5-2 kW. The fact is that external characteristic electric motors alternating current(except for three-phase with a phase rotor - complex, expensive, requiring regular care) is pretty tough. From the resistance of the bending metal, the engine does not increase the torque on the shaft, but on the contrary, the rotor slip increases and the torque drops. And the energy consumption is increasing.
The hydraulic drive, in theory, is ideal - the hydraulic cylinder itself automatically adjusts its force to the resistance of the part. But precision hydraulic systems are complex and expensive. Even an experienced designer will not undertake to distribute the force of, say, a car jack evenly along the entire length of a meter-long bend, as well as synchronize the work of two or more with improvised means.
It remains "handbrake", and it's not so bad. If you design a bender so that, as in swing rowing or powerlifting, the strongest and most enduring muscles work (biceps, latissimus dorsi, thighs, calves), and the reaction (recoil) of the machine presses the feet to the floor, then the work, due to its cyclicity, will not will be exhausting. But a skill will be developed that will give accuracy and productivity.
For example: an average person running up a flight of stairs can develop a power of about 1 hp within 1-2 seconds. But already on the third flight, the muscles will switch from oxygen to glycogen, lactic acid will begin to be released, and fatigue will hit the body. You need to take a break to move on.
For sports information: the rowers are lean, because the "kendyukh" makes it difficult to give a full go-ahead with the body. But for weightlifters, the “corn”, on the contrary, helps to keep balance when jerking. But the work of the musculature of both is in many respects similar.
Schemes and purpose
Listogib - the concept is quite general. The device of the sheet bender depends on its purpose. According to the nature of the work, you need to choose a homemade scheme, see fig.
At pos. A - a method familiar to anyone who has even a little locksmithing. So you can simply bend sheets up to 0.5 m wide with your hands. If the bend length is not more than 200-250 mm, then the base can not be attached to the workbench, but together with the clamping beam and the part, clamp it in a vice. The fold turns out to be good if you lean more on the traverse at the bottom, as shown in the diagram of forces, and move a little forward, as if smoothing out the fold. Most of the designs of home-made bending machines are based on this principle; we'll still get there.
Due to the elasticity of the metal, bending the sheet exactly at 90 degrees will not work, so spacers are used from a strip of metal, as shown in the inset. Why are there channels on the section, and not corners? Let's take a look at this issue next. elementary simple-looking design has significant nuances.
Pos. B shows how a press brake works. A press is like a press: bed-matrix-punch-hydraulics-blow-ready. These are used only in industrial production with a developed system of labor protection: they are complex, expensive, require qualified care and are extremely traumatic. A sheet that has slipped out from improper refueling or equipment malfunction can cut off a person’s hand or head.
At pos. B - broaching (through) sheet bending. By changing the mutual arrangement of the rolls, it is possible to set the bending radius of the sheet. The pass-through sheet bender can be either manual or electrically driven. Applicants to wide sale, as a rule, are multifunctional:
- Smooth rolls are designed for tinsmith work - bending shell shell blanks, sections of wide pipes, etc.
- The rolls can be replaced by complete profiled sheet-bending rolls designed for pulling roof extensions - ridges, valleys, gutters and flanging.
- Also, many models are equipped with a support, clamp and traverse for manual bending of sheets.
It is these benders that sell for $2,000 or so. Many are equipped, or later you can buy it, with shaped rollers for corrugated board, but, as already discussed, it is impossible to “drive a shaft” for sale on them. You can roll a piece if you need it right now, but it makes no sense to buy a whole sheet.
Note: there is another interesting type of bending device, but due to its high utility and relatively low cost, a separate section will be devoted to it.
We take up sheet bending
We will begin the manufacture of our bending machine with the development of the simplest specifications. And we will calculate the latter, in addition to the criteria of longevity described above, based on the consumption of muscular energy, which an average adult man is able to produce day after day without worsening his well-being. Of course, the simplicity and cheapness of the design is also not in last place. Also, the machine, in terms of weight and dimensions, must allow transportation in passenger car and application directly at the place of work. It turns out:
- The width of the bent sheet is up to 1 m.
- Thickness of the bent sheet - up to 0.6 mm galvanized; up to 0.7 mm aluminum and up to 1 mm copper.
- The number of operating cycles without readjustment and / or repair is at least 1200.
- Flexion angle - not less than 120 degrees without manual finishing; so it is necessary for folds.
- The use of special steels or non-standard blanks is highly undesirable.
- Welding - as little as possible; parts / assemblies lead from it, and welds are fragile and quickly get tired of alternating loads.
- Metalworking on the side (turning, milling) - also as little as possible, it costs money.
Let's face it: drawings of finished structures that meet all these requirements are not found in public sources. We will try to improve one, widely known, and, in principle, very successful.
We bring to mind
Incision
The principle of the device of this sheet bender is clearly visible in the section (see the figure on the right and the list of positions). Its main advantage is good ergonomics. With such a working stroke, the muscles work as they should, and the feet are pressed to the floor, which even for an inexperienced operator will give a stable result. And the maximum bending angle is 135 degrees, which is with a large margin for any conceivable and unthinkable elasticity of the bent sheet.
- wooden pillow;
- support beam - channel 100-120 mm;
- cheek - from a sheet of 6-8 mm;
- workpiece;
- clamping beam (clamp) - welded from corners 80 and 60 mm;
- traverse axis - pin 10 mm;
- rotary traverse - corner (?) 80-100 mm;
- handle - bar 10 mm.
The material of all parts is ordinary structural steel. But already here it is conditionally shown that it is better to replace the traverse from the corner with a channel of the same size. Why? Let's take a closer look, this is important for the future.
The reaction (recoil) from the bent sheet to the traverse (and clamp, but more on that later) is uneven in width. In the middle, where each elementary (tiny; this is a hint at differentiation and integration) metal section is surrounded on all sides by the same metal, it is maximum. At the edges, where there is no side support, it is minimal.
The second point is the sheet, although thin, but of finite thickness. Stresses in the workpiece will spread, reflected on the edges. As a result of the diagrams of the load on the traverse and the clamp, it will take the form of a bow with a bowstring. On the free (far) edges of the corner shelves, such a load will give a tensile force, and the metal does not work well in tension - it quickly gets tired of it. The do-it-yourselfer who built such a machine soon discovers that the corner in the middle is bent and the fold in the middle is swollen.
The side shelves of the channel are wedge-shaped, and there are more developed ones in it than in inner corner corners, fillets. This, firstly, smooths out the diagram - the bowstring is barely stretched. Secondly, the superfluous, it would seem, side flange of the channel draws tensile stresses onto itself, which are converted into compression at its free edge. And the compression holds the metal - wow!
The result of the calculation is impressive: if the traverse from the corner can withstand a couple of hundred bends at most, then the channel of the same width is more than 1200! What is 200 bends? One or a little more roof at best. At the height of the season, when customers stand in line, the machine deteriorates, and the work has stopped. And 1200 operations means that the season will survive. In winter, there will be time to trim, or replace the traverse, or, having calculated the proceeds, buy a “company” with a guarantee of a resource.
Detailing
In the next figure, there is already a detail with a list of positions. Here, not only do you need to eliminate some shortcomings, but you can also improve something further.
- clamp - corner 40-60 mm; screw M8-M10 with a knob and a heel;
- cheek;
- support beam;
- bracket - corner 110 mm;
- clamping beam;
- traverse axis;
- traverse.
pressure beam
First of all - about milling the lower surface of the clamp on the plane. It is needed for any of its designs, and the permissible unevenness is no more than half the thickness of the bent sheet (minimum! Let's assume it is equal to 0.2 mm). Otherwise, the sheet will crawl (leak) under pressure - and again a pot-bellied fold.
So for anyone who himself at least once did something for metal, the advice to smooth the clamp with a file or a grinder will only cause a smirk. It needs to be sent for cutting. Moreover, AFTER welding the entire assembly, when everything that could have happened has already happened. Otherwise, the work and payment of the router will be in vain.
Further, everything that was said above about the load on the traverse is also true for the clamp. And its most loaded part - the leading edge - is not supported by anything. It is impossible to reinforce or replace the entire assembly from the corner with a channel: the bend angle will be no more than 90 degrees.
As a result, after the same 100-200 operations, the machine will “open its mouth” (or “smile”, if you prefer white rather than black humor) and the same swollen bend. Up the clamp will not bend; in this respect it is well fortified. But the metal on the leading edge will simply leak from fatigue.
A section of the clamp design, which is equal in durability to the traverse, is shown in the inset at the top right. The basis is a steel strip 16x80 mm. The front edge is milled at 45 degrees, and a chamfer is removed on the same router for at least 2.5-3 MAXIMUM thicknesses of the bent steel sheet, i.e. 1.5-2 mm. From the deflection upward, the clamp is reinforced with a sixty-corner for welding. Milling, again, after all welding work.
The idea is this: if in the previous design the leading edge works half in bending (which is even worse for metal in tension), then in the new one it works only in compression. At the same time, the general support on the edge will not allow it to leak soon.
Note: if nearby, somewhere in a landfill, an ancient ruined lathe- the problem of the traverse with the clamp is solved once and for all. Pieces can be cut from the bed desired configuration made of special steel and excellent precision.
In terms of the number of working operations for manufacturing, both clamps are equivalent: cutting, drilling, welding, milling. The material consumption of the new clamp is higher than the old one; standard sizes of blanks for both require three. But the ratio of durability is the same as for the two types of traverses described above.
Table mount
The next step is clamps. The author of the design, of course, clearly imagines the role of stiffeners, but it seems that he has lost sight of the fragility and fatigue of welds. And the working stroke of the traverse gives a variable tensile force on the clamps with lever arms of 10:1 or more. If the clamp breaks, the work is over, even if everything else remains perfectly even. The machine will lift itself, not bend.
Why not get rid of clamps altogether? And then cheeks will not be needed, and welding for both. How to do it?
- Extend the support beam to the sides beyond the table.
- Choose U-shaped eyes at its ends.
- Fasten to the table with bolts somewhere M10 with shaped nuts - paws.
The second option is the holes in the paws without thread. The bolts are turned over and tightened with wing nuts. A little more expensive, but easier to work with.
Traverse fastening
Here the question arises: how to fix the traverse, since there are no more cheeks? Yes, they are not needed. Firstly, the design turns out to be non-separable, and the traverse will have to be changed once a year. Secondly, remember, we need an accuracy of about 0.1 mm, otherwise the fold will swell. How soon will the pin break a simple “hole” in the cheek by a large amount? The question is rhetorical. And at the same time I apologize to my fellow engineers: of course, I know that a hole is somewhere in someone, but in metalworking there is a hole.
But how then to fix the traverse? Butterfly door hinges; the lower right inset in Fig. They do not require tie-ins (invented specifically for metal doors), and two such hinges hold the door, armored from the line of "Kalash" or F-1 grenades. It takes six healthy men to put one up.
In terms of accuracy, most butterfly loops pass the bang test without difficulty. If you quickly separate the loop, then a smacking sound is heard from the air that replaces the vacuum formed when the pin is pulled out. That is, the fit of the parts is very tight, but rotate easily.
Butterflies are fastened with countersunk screws. If you put it on an iron red lead, the traverse will stand indestructibly. Opening angle - 160 degrees. Probably, the inventor of butterfly loops once made a home-made sheet bender. Such a joke.
Assembly
Finally, in front of you is an assembled sheet bender:
- support beam;
- threaded (M10) flywheel;
- clamping beam;
- processed sheet;
- clamp (see previous);
- traverse.
There is only one remark to be made here. Perhaps the author of the design had flywheel nuts lying somewhere in the stash, which is why he installed them. In fact, to put the next sheet, you will have to raise the clamp by only 2-3 mm. Well, by 30 mm, if you need to take out a picture with a fold already molded on the other side. Thread pitch M10 remember? That is, you do not need to turn the flywheels for a long time, like a gun when aiming. There are enough wing nuts or even ordinary ones with welded collars.
Note: after welding on the knobs, it is imperative to drive the thread “to the full” - by holding the nut in a vice, and with the first, and then with the second tap, or with a machine single-pass. From welding, the thread leads so that oh ...
Video: an example of a finished homemade sheet bender
Zig machine
The Zig-machine is, of course, not a robot in the form of a screaming Hitler with an outstretched hand. Zigovochnaya machine (see. Fig.) or zigmashina - a device for zigovka, or zigovirovanie. And zigovka - stretching on sheet metal flanging or special potholes - zigs. Have you seen the stiffeners on buckets and basins? This is the ridges. Actually machines for brevity are also often called zigovka
Zigovochnye machines, as follows from the definition, also belong to the category of sheet bending equipment, only special. They are either electric or manual. The latter are desktop stationary (in the figure) or portable (mobile), with a clamp. These can be carried with you in your tool bag.
Zigmashina - indispensable assistant in tin and roofing works. You can not only zig round blanks shells, but also sheets. Try on the best manual sheet bender to make a bend under the already mentioned double fold. Such a zigovka is obtained in one pass; with some skill - right on the roof. What else can be obtained by zigovka using standard pairs of rollers can be seen in the following figure. Letter designations standard; they correspond to the type of operation being performed. The zigovka costs three to five times, or even ten times cheaper than the factory manual bending machine.
Video: work on a zig machine
What to whom?
Let's summarize - which sheet bender is better for whom:
- For an amateur do-it-yourselfer - bending with improvised means, as described, or home-made manual, if there is a supply of junk and a desire to tinker.
- To the master-universal worker, who from time to time receives orders for tin or roofing - a home-made manual like the one described plus, if there is some excess of funds - a zigmachine.
- Roofer or tinsmith - a professional who has a stable flow of orders - branded manual with a sigmachine.
- For mass production of corrugated board, standard roofing elements or sheet metal structures - specialized industrial equipment corresponding destination.
Last note: for stable work results with a dense flow of orders, you still should not rely on a home-made bending machine - the metal in the structure is not the same, it will soon float from fatigue.
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